PCB High Voltage DC-DC Boost Converter

STEP 1 / STEP 2 / STEP 3

This boost converter is for those with moderate electronics experience.

This circuit only takes up 1 5/8″ x 1 1/4″ x 1″ and can operate from 8.4V to 31.2V and output maximum of 500V safely. I recommend using at least a 12V battery.

DANGER HIGH VOLTAGE
This device can put out lethal voltages and the capacitors you charge can store lethal charges for hours, Wear Electrician gloves while operating and take all safety precautions

Specifications:
Project Cost:
– $20 + Shipping Mouser
– $5 + Shipping Coilcraft PCV-2-394-05L (Follow the link and type in the part number to buy)
->=$15 + Shipping MPJA
– Average Total Cost with Shipping
— <$50–

Input Voltage: 8.4V to 31.2V
Output Voltage Range: 100V to 500V
Output Power:

– TEST 1-12V Input 48W max +-20% Charged 290J Capacitor Bank in 6s
– TEST 2 – 12V Input 45W max +-20% Charged 1160J Capacitor Bank in 26s
– 24V Input TBD

Output Power Measured with 1-2 12V 34Ah Lead Acid Batteries for a VirtuallyConstant Voltage Source
Each test was done 5 times, the best of which is shown.

The Major limitation of how much power can be drawn from your batteries is the Battery Packs ESR

—For Best results used high current rated batteries or Batteries meant for Power RC Devices—NiCd are the best(with the exception of Li-poly)
For The Following Batteries an Estimated Maximum Power can be drawn
ESR = Equivalent Series Resistance = Internal Resistance

Alkaline can be used, but I strongly recommend Rechargeable high current rated batteries.
Lower Voltages May be used, but expect a Lower Power Output.

NiCD/NiMH
12V AAA ESR = 350-400mOhm 28-30W
12V AA ESR = 150-300mOhm 31-34W
24V AAA ESR = 700-800mOhm 60-80W
24V AA ESR = 300-600mOhm 75-85W

BATTERY WARNING

Drawing too much current from your batteries may reduce there capacity, life, and cause your battery to over heat, Monitor Your Batteries temperature. If using LiPoly please use a battery protector or protection circuit. If this circuit fails it can short and cause the LiPoly battery to over heat and catch fire.
STEP 1 / STEP 2 / STEP 3